Systems and methods for recycling post-consumer polyester-based fabric

ABSTRACT

Methods for recycling post-consume polyester-based fabric materials such as hospital linens. The methods include decontaminating a post-consumer polyethylene terephthalate (PET) product and polymerizing the decontaminated PET product via solid state polymerization to generate a polymerized PET product. The post-consumer PET product may include a polyester-based fabric. The post-consumer PET product may retain essentially the same shape and form during and after recycling and decontamination as before recycling.

This application is a US National Phase application based on PCTApplication No. PCT/US17/60017, filed Nov. 3, 2017, which claimspriority to U.S. Provisional Patent Application Ser. No. 62/417,071,entitled SYSTEM AND METHODS FOR RECYCLING POST-CONSUMER POLYESTER-BASEDFABRIC, filed on Nov. 3, 2016, each of which is incorporated herein byreference in its entirety.

BACKGROUND

The present disclosure generally relates to systems and methods forrecycling post-consumer polyester-based fabrics. More particularly, someimplementations of the present disclosure relate to systems and methodsfor recycling soiled hospital bedding comprising polyester-basedfabrics.

A number of service industries such as hospitals, medical clinics,hotels and other hospitality providers, gyms, health clubs, and similarservice providers generate large amounts of soiled clothing, linens,bedding, towels, and other fabric-based items. It can be challenging toproperly clean and/or decontaminate these fabric-based items. It canalso be time-consuming, costly, labor-intensive, and harmful to theenvironment. In particular, properly cleaning and decontaminating soiledhospital linens can be especially problematic. For example, each year inthe United States, hospitals generate an estimated six billion pounds ofsoiled hospital linens. These soiled hospital linens can constitute alarge source of infectious contamination that must be properly cleanedand decontaminated before being returned to service to preventcross-contamination throughout the hospital facility.

Conventional methods of cleaning and decontaminating soiled hospitallinens involve labor-intensive laundering of the soiled hospital linens.This laundering of the soiled hospital linens may require tens tohundreds of millions of gallons of water in a single year by a singlefacility. Additionally, strict protocols for collecting, transporting,processing, and storing clean and soiled hospital linens must befollowed to limit infection of patients, staff, and medicalpractitioners. In some cases, single-use or limited-use hospital linenscomprising polyester-based fabrics can reduce the need to launder soiledhospital linens. While these single-use or limited-use polyester-basedlinens can be discarded after use, it can be harmful to the environmentto discard these items after use. Furthermore, conventional methods arelimited in their ability to recycle these soiled single-use orlimited-use polyester-based linens.

Thus, while conventional methods of cleaning and decontaminating soiledhospital linens currently exist, challenges still exist, including thoselisted above. Accordingly, it would be an improvement in the art toaugment or even replace current techniques with other techniques.

BRIEF SUMMARY

The present disclosure generally relates to systems and methods forrecycling post-consumer polyester-based fabrics. The methods cancomprise decontaminating a post-consumer polyethylene terephthalate(PET) product to remove one or more of infectious waste, tissue, andcolorants and polymerizing the decontaminated PET product via solidstate polymerization to generate a polymerized PET product. Thepost-consumer PET product can comprise post-consumer PET product that issubstantially unaltered from its pre-consumer form. The post-consumerPET product can comprise a PET-based woven or non-woven fabric. ThePET-based woven or non-woven fabric can comprise a thickness of no morethan 1 mm. The PET-based woven or non-woven fabric can comprise soiledhospital bedding.

In some cases, decontaminating can comprise incubating the post-consumerPET product in a stirred vessel with solvent. Decontaminating cancomprise incubating at between about 50° C. and about 200° C.Decontaminating can comprise incubating at between about 90 kPa andabout 200 kPa. Decontaminating can also comprise incubating for betweenabout 15 minutes and about 100 minutes. In other cases, the solvent cancomprise one or more of ethanol, benzene, ethylene glycol, propyleneglycol, water, and acetone. In yet other cases, the solvent can becontinuously filtered. The filtering can include filtering with amembrane-type filter, filtering with a screen filter, filtering withactive carbon, and filtering with a belt-filter. Decontamination canalso include removing the solvent after incubation and drying thedecontaminated PET product.

In some instances, solid state polymerization can comprise heating thedecontaminated PET product to a temperature of between about 190° C. andabout 230° C. In other instances, heating is carried out under a vacuum.In yet other instances, heating is carried out in an inert gasatmosphere. The inert gas atmosphere can comprise one or more ofnitrogen, helium, and argon. The solid state polymerization can becarried out for between about 8 hours and about 48 hours.

In some embodiments, the method further comprises converting thepolymerized PET product into pellets. In other embodiments, the pelletsare no more than about 1 mm in diameter. In yet other embodiments, themethods include extruding the polymerized PET product into a syntheticfiber. In some cases, the method includes extruding the polymerized PETproduct into sheets. In other cases, decontaminating further comprisesremoving one or more of human waste, biomedical waste, tissue, skin,hair, blood, urine, feces, bodily fluids, clinical waste, medical waste,inks, dyes, and dirt. In yet other cases, the method includes shreddingthe post-consumer PET product to a size range of between about 2 cm andabout 5 cm. The method can further comprise removing any elasticmaterial from the shredded post-consumer polyethylene terephthalate(PET) materials.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

In order that the above-recited and other features and advantages of thedisclosure are obtained and will be readily understood, a moreparticular description of the disclosure briefly described above will berendered by reference to specific embodiments thereof, which areillustrated in the appended drawings. These drawings depict only typicalembodiments of the disclosure and are not therefore to be considered tolimit the scope of the disclosure.

FIG. 1 illustrates some embodiments of a PET molecule.

FIG. 2 illustrates a flow diagram of some embodiments of a process forrecycling post-consumer polyester-based fabrics.

DETAILED DESCRIPTION

The presently preferred embodiments of the present disclosure will bebest understood by reference to the drawings, wherein like referencenumbers indicate identical or functionally similar elements. It will bereadily understood that the components of the present disclosure, asgenerally described and illustrated in the figures herein, could bearranged and designed in a wide variety of different configurations.Thus, the following more detailed description, as represented in thefigures, is not intended to limit the scope of the disclosure asclaimed, but is merely representative of presently preferred embodimentsof the disclosure.

The present disclosure relates to systems and methods for recyclingpost-consumer polyester-based fabrics. More particularly, someembodiments of the present disclosure relate to systems and methods forrecycling soiled hospital linens comprising polyester-based fabrics.While the systems and methods can comprise any suitable step and/orcomponent, in some cases, they include providing post-consumer PETproduct, decontaminating the post-consumer PET product, polymerizing thedecontaminated PET product, and forming products from the polymerizedPET product. Additionally, in some embodiments, the systems and methodsinclude polymerizing the decontaminated PET product via solid statepolymerization.

In the disclosure and the claims, the term PET (and variations thereofsuch as PETE) can be used to refer to a thermoplastic polymer resin ofthe polyester family comprising the chemical formula (C10H8O4)n. FIG. 1illustrates a chemical structure of a PET molecule 1. PET can also beknown as polyethylene terephthalate or poly(ethylbenzene-1,4-dicarboxylate). In some cases, PET can comprise othercondensation polymers made by melt polymerization (e.g., PET, PBT, PEN,PEN/PET, PTT, PA6, PA66, PA46, PPS, and LCP). In other cases, PET canalso comprise the plastic recycling code “1”.

In some embodiments, a polyester-based fabric comprises PET. Thepolyester-based fabric can comprise PET fibers, PET yarn, and/or PETthreads that are formed into a fabric or textile. In some cases, thepolyester-based fabric can comprise woven PET fibers, PET yarn, and/orPET threads. In other cases, the polyester-based fabric can comprise anon-woven fabric. The polyester-based fabric can also comprise PET-basedfabrics known by the tradenames, DACRON, TERYLENE, LAVSAN, TETORON,DIOLEN, ELANA, and TERGAL. While the polyester-based fabric can compriseany suitable thickness, in some cases, the polyester-based fabriccomprises a thickness of less than about 3 mm. In other cases, thepolyester-based fabric comprises a thickness of less than about 2 mm. Inyet other cases, the polyester-based fabric comprises a thickness of notmore than about 1 mm. In some instances, the polyester-based fabriccomprises a thickness of about 0.1 mm to about 2.0 mm, and subrangesthereof. In other instances, the polyester-based fabric comprises athickness of about 0.1 mm, 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7mm, 0.8 mm, 0.9 mm, 1.0 mm, 1.1 mm, 1.2 mm, 1.3 mm, 1.4 mm, 1.5 mm, 1.6mm, 1.7 mm, 1.8 mm, 1.9 mm, or 2.0 mm. In yet other instances, thepolyester-based fabric comprises PET fibers comprising an intrinsicviscosity of between about 0.40 dL/g to about 0.70 dL/g.

In some embodiments, the polyester-based fabric is used to produce itemsfor hospital use such as bedding and linens. The polyester-based fabriccan also be used to produce items for hospital use including, but notlimited to, linens, bedding, bed sheets, fitted sheets, blankets,medical scrubs, hospital gowns, pajamas, robes, towels, washcloths,handkerchiefs, head coverings, curtains, surgical drapes, hospital shoecovers, uniforms, socks, lab coats, and aprons. In other embodiments,the polyester-based fabric can be used to produce any items for hospitaluse that are customarily made from fabric such as the items describedabove. In yet other embodiments, the polyester-based fabric can be usedto produce items for the hospitality industry including but not limitedto, linens, bedding, bed sheets, fitted sheets, blankets, pajamas,robes, towels, washcloths, handkerchiefs, head coverings, curtains,uniforms, socks, tablecloths, napkins, bibs, and aprons.

In some embodiments, the polyester-based fabric is used to produce itemsthat are configured for single-use or for limited-use. In some cases,single-use items can be configured to be used only one time. In othercases, limited-use items can be configured to be used for a limitednumber of uses (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 uses). Forexample, hospital linens can be configured as single-use or limited-useitems and can be configured to be used for a single patient and/or forlimited amount of time (e.g., 1, 2, 3, 4, 5, 6, or 7 days). An advantageof single-use or limited-use items is that the items can be less costlyto manufacture because the items do not need to be designed forlong-term use. Another advantage of single-use or limited-use items isthat the items do not have to be cleaned and/or decontaminated after useso that they can be used again. For example, hospital linens configuredas single-use or limited-use items can be discarded and/or recycledafter use and do not need to be cleaned and/or decontaminated for reusethereby reducing the need for laundering services and the risk ofcross-contamination of patients, staff, and medical practitioners. Inyet other cases, any of the items described above for hospital useand/or hospitality use can comprise polyester-based fabric and can beconfigured for single-use or limited-use. In some instances,polyester-based fabric can be configured for single-use or limited-usefabric items in any industry where single-use or limited-use fabricitems may be beneficial.

In general, some embodiments of the described systems and methods relateto recycling post-consumer polyester-based fabric. While the systems andmethods can comprise any suitable step and/or component, FIG. 2 showsthat, at least in some cases, a method 10 for recycling post-consumerpolyester-based fabric can comprise a providing post-consumer PETproduct step 100, a decontaminating step 200, a polymerizing step 300,and a forming products from the polymerized PET product step 400.

With respect to the providing post-consumer PET product step 100, thestep 100 can include any suitable step to provide suitable post-consumerPET product to be recycled. For example, in some embodiments the step100 can include drying the post-consumer PET product, such as byexposing the post-consumer PET product in a dry air environment at atemperature between 100° C. and 140° C. In this way, the step 100removes any solvents and/or water molecules from the post-consumer PETproduct prior to further processing and/or recycling.

In some embodiments, the suitable post-consumer PET product comprisessoiled single-use or limited-use polyester-based hospital linens. Thesoiled single-use or limited-use polyester-based hospital linens can beprovided in any suitable manner to the method 10. For example, thesoiled hospital linens can be sealed in a plastic bag to preventcross-contamination and for ease of transport. In some cases, multiplesoiled hospital linens can be sealed in a plastic bag. The sealed soiledhospital linens can then be stacked on pallets in groups of about 100pounds to about 500 pounds and then transported to a recycling facility.An advantage of sealing the soiled hospital linens in this manner isthat no hospital staff comes into contact with the soiled hospitallinens after they are sealed and the risk of infection and/or crosscontamination is reduced. Other types of suitable post-consumer PETproduct (e.g., soiled towels, blankets, robes, hospital scrubs) can besealed and transported in the same manner.

In some embodiments, the post-consumer PET product is provided in a formthat is substantially unaltered from a pre-consumer form and subjectedto the decontaminating step 200 in this substantially unaltered form.For example, soiled single-use or limited-use polyester-based hospitallinens can be provided in this substantially unaltered form as bedsheets. These soiled single-use or limited-use polyester-based hospitallinens can be decontaminated without shredding, cutting, or rending ofthe linens. An advantage of providing and decontaminating the soiledsingle-use or limited-use polyester-based hospital linens in asubstantially unaltered form is reduced cost and reduced processingtime. Another advantage of providing and decontaminating the soiledsingle-use or limited-use polyester-based hospital linens in asubstantially unaltered form is that the thickness of the bed sheets inthe pre-consumer form is already conducive to solid state polymerizationin the polymerizing step 300.

In some embodiments, the post-consumer PET product is processed beforedecontamination. This processing can reduce the size of thepost-consumer PET product. For example, soiled single-use or limited-usepolyester-based hospital linens can be shredded into smaller pieces. Insome cases, the soiled single-use or limited-use polyester-basedhospital linens can be shredded into pieces between 1 cm and 10 cm inlength. In other cases, the soiled single-use or limited-usepolyester-based hospital linens can be shredded into pieces between 2 cmand 5 cm in length. In some instances, the shredded pieces can befurther processed to remove any elastic material (e.g., elastic materialfrom fitted bed sheets). The elastic material can be removed by one ormore of gravimetric differences, flotation, vibration, or by a rotarysystem.

In some embodiments, decontaminating step 200 comprises removing anysoiling from the post-consumer PET product. Decontaminating 200 alsoincludes removing any contaminants from the post-consumer PET product.For example, soiled single-use or limited-use polyester-based hospitallinens can be contaminated with any number of contaminants from use bypatients, staff members, and medical practitioners. Contaminants caninclude, but are not limited to, infectious waste, tissue, colorants,inks, dyes, human waste, biomedical waste, tissue, skin, hair, blood,sweat, tears, urine, feces, bodily fluids, clinical waste, medicalwaste, food, and dirt. In some cases, decontaminating 200 also comprisessterilizing the post-consumer PET product. Sterilizing can include oneor more of removing, inactivating, denaturing, killing, and eliminatinga pathogen. Pathogens can include one or more of microbes, bacteria,fungi, virus, parasites, prions, and other infectious particles.

Although decontaminating 200 can comprise any suitable step or componentto remove soiling, remove contaminants, and sterilize, at least in somecases, decontaminating 200 can comprise incubating the post-consumer PETproduct with a solvent in an enclosed vessel. The post-consumer PETproduct can be stirred as it is incubated in the enclosed vessel. Insome cases, the post-consumer PET product can be incubated at betweenabout 20° C. and about 200° C., and any subranges thereof. In othercases, the post-consumer PET product can be incubated at between about50° C. and about 200° C., and any subranges thereof. In yet other cases,the post-consumer PET product can be incubated at about 50° C., about60° C., about 70° C., about 80° C., about 90° C., about 100° C., about110° C., about 120° C., about 130° C., about 140° C., about 150° C.,about 160° C., about 170° C., about 180° C., about 190° C., or about200° C. In some instances, an incubation temperature can be adjustedbased on a level of soiling of the post-consumer PET product. In otherinstances, the incubation temperature can be adjusted based on a type ofsoiling of the post-consumer PET product.

In some cases, the post-consumer PET product can be incubated at betweenabout 0 kPa and about 200 kPa, and any subranges thereof. In othercases, the post-consumer PET product can be incubated at between about90 kPa and about 200 kPa, and any subranges thereof. In yet other cases,the post-consumer PET product can be incubated at about 90 kPa, about100 kPa, about 110 kPa, about 120 kPa, about 130 kPa, about 140 kPa,about 150 kPa, about 160 kPa, about 170 kPa, about 180 kPa, about 190kPa, or about 200 kPa. In some instances, an incubation pressure can beadjusted based on a level of soiling of the post-consumer PET product.In other instances, the incubation pressure can be adjusted based on atype of soiling of the post-consumer PET product.

In some cases, the post-consumer PET product can be incubated at betweenabout 1 minute and about 180 minutes, and any subranges thereof. Inother cases, the post-consumer PET product can be incubated at betweenabout 15 minute and about 100 minutes, and any subranges thereof. In yetother cases, the post-consumer PET product can be incubated about 10minutes, about 20 minutes, about 30 minutes, about 40 minutes, about 50minutes, about 60 minutes, about 70 minutes, about 80 minutes, about 90minutes, or about 100 minutes. In some instances, an incubation time canbe adjusted based on a level of soiling of the post-consumer PETproduct. In other instances, the incubation time can be adjusted basedon a type of soiling of the post-consumer PET product.

In some embodiments, the solvent comprises any suitable liquid toeffectively remove soiling, remove contaminants, and sterilize thepost-consumer PET product. For example, the solvent can comprise one ormore of an aqueous liquid, an organic solvent, and an alcohol. Thesolvent can also comprise additives such as surfactants, detergents, andionic additives. The solvent can also be applied in sequentially inbatches and can comprise different liquids for each batch. In somecases, the solvent comprises one or more of ethanol, benzene, ethyleneglycol, propylene glycol, acetone, water, and other related liquids. Inother embodiments, the solvent is filtered during incubation. Thesolvent can be filtered with one or more of a membrane type filter, ascreen filter, an activated carbon filter, and a belt filter. In someinstances, the post-consumer PET product can be incubated in the solventin a batch mode configuration. In other instances, the post-consumer PETproduct can be incubated in the solvent in a continuous modeconfiguration with the post-consumer PET product moved from one vesselto another by positive-displacement pumps. In some instances, acomposition of the solvent can be adjusted based on a level of soilingof the post-consumer PET product. In other instances, the composition ofthe solvent can be adjusted based on a type of soiling of thepost-consumer PET product. In yet other instances, the filtering of thesolvent can be adjusted based the on level of soiling of thepost-consumer PET product and/or the type of soiling of thepost-consumer PET product. After incubating, the solvent can be removedby one or more of centrifuge, press filter, and rotary dryer.

In some embodiments, polymerizing step 300 comprises polymerizing thedecontaminated post-consumer PET product via solid state polymerizationto generate a polymerized PET product. In some cases, solid statepolymerization can be configured to enhance mechanical and rheologicalproperties of the polymerized PET product. In other cases, solid statepolymerization can be configured to increase polymer chain lengths inthe decontaminated post-consumer PET product to generate the polymerizedPET product. In yet other cases, solid state polymerization can beconfigured to increase a molecular weight of polymers in thedecontaminated post-consumer PET product to generate the polymerized PETproduct.

In some cases, solid state polymerization can be carried out by heatingthe decontaminated post-consumer PET product at a temperature above theglass transition temperature (Tg) of PET and below the meltingtemperature (Tm) of PET. In some instances, the heating can be carriedout in the absence of water and oxygen to reduce undesirable sidereactions. Often the heating can be carried out under vacuum or under aninert gas (e.g., nitrogen, helium, and argon) to remove water and oxygento reduce undesirable side reaction. In other instances, because PET canbe hygroscopic, the decontaminated post-consumer PET product can beheated to drive off moisture. In yet other instances, the decontaminatedpost-consumer PET product can be heated to drive off moisture to a levelbelow about 50 ppm. The heating can be carried out under vacuum or underan inert gas to reduce undesirable side reactions and/or to removeundesirable by-products such as ethylene glycol and acetaldehyde. Solidstate polymerization can be affected by a number of parameters such astemperature, pressure, and diffusion of by-products from an interior ofthe PET product to a surface of the PET product. Therefore, in someinstances, a size (e.g., a thickness) of the PET product subjected tosolid state polymerization can affect one or more of the rate,efficiency and quality of the solid state polymerization. In some cases,a PET product with a thinner diameter and/or a reduced thickness canpermit greater diffusion of by-products from the interior of the PETproduct to the surface of the PET product and can thereby improve solidstate polymerization.

In some embodiments, solid state polymerization is carried out bycontinuously feeding the decontaminated PET product into a tool thatheats the product to between about 190° C. and about 230° C. under aheated nitrogen stream. In some cases, the temperature can be about 190°C., 195° C., 200° C., 205° C., 210° C., 215° C., 220° C., 225° C., and230° C. A carrying system for the decontaminated post-consumer PETproduct can allow for continuous heating of the product and continuousheated nitrogen flow for between about 8 hours and about 48 hours. Inother cases, the decontaminated post-consumer PET product can becontinuously heated with continuous heated nitrogen flow for about 8hours, about 10 hours, about 15 hours, about 20 hours, about 25 hours,about 30 hours, about 35 hours, about 40 hours, about 45 hours, andabout 48 hours.

In some cases, the decontaminated PET product comprises single-use orlimited-use polyester-based fabric. In other cases, the decontaminatedPET product comprises post-consumer PET product is provided in a formthat is substantially unaltered from a pre-consumer form and subjectedto the decontaminating step 200 in this substantially unaltered form.For example, decontaminated hospital linens substantially unaltered froma pre-consumer form can be fed directly into the tool for heating underthe heated nitrogen stream. An advantage is that the relatively reducedthickness of the decontaminated hospital linens substantially unalteredfrom a pre-consumer form (e.g., no more than 1 mm) can permit greaterdiffusion of by-products from the interior of the PET product to thesurface of the PET product and can thereby improve solid statepolymerization.

In some embodiments, polymerizing 300 comprises melting and formingpellets from the decontaminated post-consumer PET product followed bysolid state polymerization of the formed pellets. While the pellets cancomprise any suitable shape, at least in some cases, the pellets cancomprise a diameter of between about 0.1 mm and about 5 mm. In othercases, the pellets can comprise a diameter of between about 0.5 mm andabout 1.5 mm. In yet other cases, the pellets can comprise a diameter ofno more than about 1 mm. After the pellets are formed, they can besubjected to solid state polymerization as described above by feedingthem into a tool that heats the product to between about 190° C. andabout 230° C. under a heated nitrogen stream for between about 8 toabout 48 hours. The polymerized pellets can then be packaged and sold asa commodity or can be formed into a polymerized PET product.

In some embodiments, forming polymerized PET product step 400 comprisesforming one or more products from the polymerized PET product. In somecases, the polymerized PET product is received hot from the solid statepolymerization and further heated to melt it. This molten polymerizedPET product can then formed into items. In some cases, the moltenpolymerized PET product can be shaped into pellets. The pellets can beallowed to cool and can then be packaged and sold as a commodity or usedto make other PET products. In other cases, the molten polymerized PETproduct can be extruded into a synthetic fiber. This synthetic fiber canthen be sold as a commodity or can be used to generate polyester-basedfabric. In other cases, the polyester-based fabric can be used togenerate fabric items such as single-use or limited-use hospital linens.In other embodiments, the molten polymerized PET product can beconverted into PET plastic sheets or other types of extruded materials(e.g. sheeting, strapping, packaging, etc.).

The systems and methods for recycling post-consumer polyester-basedfabric can have several useful features. For example, the disclosedmethods and systems do not require that the polymers of the recycledpolyester-based fabric be broken down into individual monomers and/oroligomers as part of the recycling process. In contrast, the polymers ofthe recycled polyester-based fabric are polymerized through solid statepolymerization. Also, the disclosed methods and systems can recycle thepolyester-based fabric while the fabric remains in a substantiallyunaltered form from the pre-consumer form. By recycling the fabric in asubstantially unaltered form from the pre-consumer form, time, energy,and resources are saved. An example is recycling bedding (e.g., a bedsheet) comprising polyester-based fabric by decontaminating,polymerizing, and generating a recycled bed sheet.

The present invention may be embodied in other specific forms withoutdeparting from its structures, methods, or other essentialcharacteristics as broadly described herein and claimed hereinafter. Thedescribed embodiments are to be considered in all respects only asillustrative, and not restrictive. The scope of the invention is,therefore, indicated by the appended claims, rather than by theforegoing description. All changes that come within the meaning andrange of equivalency of the claims are to be embraced within theirscope.

The invention claimed is:
 1. A method for recycling a polyethyleneterephthalate (PET) consumer product, said PET consumer product beingnew and comprising a geometric shape prior to consumer use, and said PETconsumer product being used and comprising the geometric shape and asoiling substance comprising one or more of infectious waste, tissue,and colorants subsequent to consumer use, the method comprising:selecting a used PET consumer product comprising the geometric shape andthe soiling substance; decontaminating the used PET consumer product toremove the soiling substance to provide a decontaminated used PETconsumer product comprising the geometric shape; and polymerizing thedecontaminated used PET consumer product via solid state polymerizationto generate a decontaminated and polymerized used PET consumer product,wherein the decontaminated and polymerized used PET consumer productcomprises the geometric shape.
 2. The method of claim 1, wherein theused PET consumer product is a woven or non-woven fabric material. 3.The method of claim 2, wherein a thickness of the woven or non-wovenfabric is less than or equal to 1 mm.
 4. The method of claim 1, whereinthe used PET consumer product comprises soiled hospital bedding.
 5. Themethod of claim 1, wherein the step of decontaminating further comprisesincubating the used PET product in a stirred vessel with a solvent. 6.The method of claim 1, wherein the step of decontaminating comprisesincubating at between about 50° C. and about 200° C.
 7. The method ofclaim 1, wherein the step of decontaminating comprises incubating atbetween about 90 kPa and about 200 kPa.
 8. The method of claim 1,wherein the step of decontaminating comprises incubating for betweenabout 15 minutes and about 100 minutes.
 9. The method of claim 5,wherein the solvent is selected from the group consisting of ethanol,benzene, ethylene glycol, propylene glycol, water, and acetone.
 10. Themethod of claim 5, further comprising a step for continuously filteringthe solvent.
 11. The method of claim 10, wherein the step ofcontinuously filtering the solvent comprises one or more of filteringwith a membrane-type filter, filtering with a screen filter, filteringwith active carbon, and filtering with a belt-filter.
 12. The method ofclaim 5, further comprising steps for: removing the solvent afterincubation; and drying the decontaminated PET product.
 13. The method ofclaim 1, wherein the step of polymerizing comprises a step for heatingthe decontaminated used PET product to a temperature of between about190° C. and about 230° C.
 14. The method of claim 13, wherein the stepfor heating is carried out under a vacuum.
 15. The method of claim 13,wherein the step for heating is carried out in an inert gas atmosphereconsisting of one or more of nitrogen, helium, and argon.
 16. The methodof claim 1, wherein the step of polymerizing is carried out for betweenabout 8 hours and about 48 hours.
 17. The method of claim 1, furthercomprising a step for converting the polymerized PET product intopellets having a diameter of approximately 1 mm.
 18. The method of claim1, further comprising a step for extruding the polymerized PET productinto a synthetic fiber.
 19. The method of claim 1, further comprising astep for extruding the polymerized PET product into a sheet material.20. The method of claim 1, further comprising a step for drying the usedPET consumer product following the step of decontaminating the used PETconsumer product and prior to the step of polymerizing thedecontaminated used PET consumer product.